Aprovechamiento térmico de residuos estériles de carbón para generación eléctrica mediante tecnologías de combustión y gasificación eficientes y con mínimo impacto ambiental

La presente tesis doctoral, “Aprovechamiento térmico de residuos estériles de carbón para generación eléctrica mediante tecnologías de combustión y gasificación eficientes y con mínimo impacto ambiental”, desarrolla la valorización energética de los residuos del carbón, estériles de carbón, producidos durante las etapas de extracción y lavado del carbón. El sistema energético se encuentra en una encrucijada, estamos asistiendo a un cambio en el paradigma energético y, en concreto, en el sector de la generación eléctrica. Se precipita un cambio en la generación y el consumo eléctricos. Una mayor concienciación por la salud está forzando la contención y eliminación de agentes contaminantes que se generan por la utilización de combustibles fósiles de la forma en la que se viene haciendo. Aumenta la preocupación por el cambio climático y por contener en 2°C el aumento de la temperatura de la Tierra para final de este siglo, circunstancia que está impulsando el desarrollo e implantación definitiva de tecnología de control y reducción de emisiones CO2. Generar electricidad de una manera sostenible se está convirtiendo en una obligación. Esto se materializa en generar electricidad respetando el medioambiente, de una forma eficiente en la utilización de los recursos naturales y a un coste competitivo, pensando en el desarrollo de la sociedad y en el beneficio de las personas. En la actualidad, el carbón es la principal fuente de energía utilizada para generar electricidad, y su empleo presenta la forma de energía más barata para mejorar el nivel de vida de cualquier grupo y sociedad. Además, se espera que el carbón siga presente en el mix de generación eléctrica, manteniendo una significativa presencia y extrayéndose en elevadas cantidades. Pero la producción de carbón lleva asociada la generación de un residuo, estéril, que se produce durante la extracción y el lavado del mineral de carbón. Durante décadas se ha estudiado la posibilidad de utilizar el estéril y actualmente se utiliza, en un limitado porcentaje, en la construcción de carreteras, terraplenes y rellenos, y en la producción de algunos materiales de construcción. Esta tesis doctoral aborda la valorización energética del estéril, y analiza el potencial aprovechamiento del residuo para generar electricidad, en una instalación que integre tecnología disponible para minimizar el impacto medioambiental. Además, persigue aprovechar el significativo contenido en azufre que presenta el estéril para producir ácido sulfúrico (H2SO4) como subproducto de la instalación, un compuesto químico muy demandado por la industria de los fertilizantes y con multitud de aplicaciones en otros mercados. Se ha realizado el análisis de caracterización del estéril, los parámetros significativos y los valores de referencia para su empleo como combustible, encontrándose que su empleo como combustible para generar electricidad es posible. Aunque en España se lleva extrayendo carbón desde principios del siglo XVIII, se ha evaluado para un período más reciente la disponibilidad del recurso en España y la normativa existente que condiciona su aplicación en el territorio nacional. Para el período evaluado, se ha calculado que podrían estar disponibles más de 68 millones de toneladas de estéril susceptibles de ser valorizados energéticamente. Una vez realizado el análisis de la tecnología disponible y que podría considerarse para emplear el estéril como combustible, se proponen cuatro configuraciones posibles de planta, tres de ellas basadas en un proceso de combustión y una de ellas en un proceso de gasificación. Tras evaluar las cuatro configuraciones por su interés tecnológico, innovador y económico, se desarrolla el análisis conceptual de una de ellas, basada en un proceso de combustión. La instalación propuesta tiene una capacidad de 65 MW y emplea como combustible una mezcla de carbón y estéril en relación 20/80 en peso. La instalación integra tecnología para eliminar en un 99,8% el SO2 presente en el gas de combustión y en más de un 99% las partículas generadas. La instalación incorpora una unidad de producción de H2SO4, capaz de producir 18,5 t/h de producto, y otra unidad de captura para retirar un 60% del CO2 presente en la corriente de gases de combustión, produciendo 48 tCO2/h. La potencia neta de la planta es 49,7 MW. Se ha calculado el coste de inversión de la instalación, y su cálculo resulta en un coste de inversión unitario de 3.685 €/kW. ABSTRACT The present doctoral thesis, “Thermal utilisation of waste coal for electricity generation by deployment of efficient combustion and gasification technologies with minimum environmental impact”, develops an innovative waste-to-energy concept of waste coals produced during coal mining and washing. The energy system is at a dilemma, we are witnessing a shift in the energy paradigm and specifically in the field of electricity generation. A change in the generation and electrical consumption is foreseen. An increased health consciousness is forcing the containment and elimination of pollutants that are generated by the use of fossil fuels in the way that is being done. Increasing concern about climate change and to contain the rise of global temperature by 2°C by the end of this century, is promoting the development and final implementation of technology to control and reduce the CO2 emission. Electricity generation in a sustainable manner is becoming an obligation. This concept materialised in generating electricity while protecting the environment and deployment of natural resources at a competitive cost, considering the development of society and people´s benefit. Currently, coal is the main source of energy employ to generate electricity, and its use represents the most cost competitive form of energy to increase the standard of living of any group or society. Moreover, coal will keep playing a key role in the global electricity generation mix, maintaining a significant presence and being extracting in large amounts. However, coal production implies the production of waste, termed waste coal or culm in Pennsylvania anthracite extraction, produced during coal mining and coal washing activities. During the last decades, the potential use of waste coal has been studied, and currently, in a limited amount, waste coal is used in roads construction, embankments and fillings, and to produce some construction materials. This doctoral thesis evaluates the waste to energy of waste coals and assesses its potential use to generate electricity, implementing available technology to minimise the environment impact. Additionally, it pursues the significant advantage that presents sulphur content in waste coal to produce sulphuric acid (H2SO4) as a byproduct of the waste-to-energy process, a chemical compound highly demanded by the fertiliser industry and many applications in other markets. It analyses the characteristics of waste coal, and assesses the significant parameters and reference values for its use as fuel, being its fuel use for electricity generation very possible. While mining coal is taking place in Spain since the 1700s, it has been evaluated for a more recent period the waste coal available in Spain and the existing legislation that affects its application and deploy to generate electricity in the country. For the evaluation period has been calculated that may be available more than 68 million tons of waste coal that can be waste-toenergy. The potential available technology to deploy waste coal as fuel has been evaluated and assessed. After considering this, the doctoral thesis proposes four innovative alternatives of facility configuration, three of them based on a combustion process and one in a gasification process. After evaluating the four configurations for its technological, innovative and economic interest, the conceptual analysis of one of alternatives, based on a combustion process, takes place. The proposed alternative facility developed has a capacity of 65 MW, using as fuel a mixture of coal and waste coal 80/20 by weight. The facility comprises technology to remove 99.8% SO2 present in the flue gas and more than 99% of the particles. The facility includes a unit capable of producing 18.5 t/h of H2SO4, and another capture facility, removing 60% of CO2 present in the flue gas stream, producing 48 tCO2/h. The net capacity of the power station is 49.7 MW. The facility unitary cost of investment is 3,685 €/kW.

Cup Anemometer's loss of performance due to ageing process, and its effect on Annual energy Production (AEP) estimates

The deviation of calibration coefficients from five cup anemometer models over time was analyzed. The analysis was based on a series of laboratory calibrations between January 2001 and August 2010. The analysis was performed on two different groups of anemometers: (1) anemometers not used for any industrial purpose (that is, just stored); and (2) anemometers used in different industrial applications (mainly in the field—or outside—applications like wind farms). Results indicate a loss of performance of the studied anemometers over time. In the case of the unused anemometers the degradation shows a clear pattern. In the case of the anemometers used in the field, the data analyzed also suggest a loss of performance, yet the degradation does not show a clear trend. A recalibration schedule is proposed based on the observed performances variations

On track for solar grade silicon through a siemens process-type laboratory reactor: operating conditions and energy savings

Polysilicon cost impacts significantly on the photovoltaics (PV) cost and on the energy payback time. Nowadays, the besetting production process is the so called Siemens process, polysilicon deposition by chemical vapor deposition (CVD) from Trichlorosilane. Polysilicon purification level for PV is to a certain extent less demanding that for microelectronics. At the Instituto de Energía Solar (IES) research on this subject is performed through a Siemens process-type laboratory reactor. Through the laboratory CVD prototype at the IES laboratories, valuable information about the phenomena involved in the polysilicon deposition process and the operating conditions is obtained. Polysilicon deposition by CVD is a complex process due to the big number of parameters involved. A study on the influence of temperature and inlet gas mixture composition on the polysilicon deposition growth rate, based on experimental experience, is shown. Moreover, CVD process accounts for the largest contribution to the energy consumption of the polysilicon production. In addition, radiation phenomenon is the major responsible for low energetic efficiency of the whole process. This work presents a model of radiation heat loss, and the theoretical calculations are confirmed experimentally through a prototype reactor at our disposal, yielding a valuable know-how for energy consumption reduction at industrial Siemens reactors.

Assessment of Hydrogen as suistinable clean energy

The progressive depletion of fossil fuels and their high contribution to the energy supply in this modern society forces that will be soon replaced by renewable fuels. But the dispersion and alternation of renewable energy production also undertake to reduce their costs to use as energy storage and hydrogen carrier. It is necessary to develop technologies for hydrogen production from all renewable energy storage technologies and the development of energy production from hydrogen fuel cells and cogeneration and tri generation systems. In order to propel this technological development discussed where the hydrogen plays a key role as energy storage and renewable energy, the National Centre of Hydrogen and Fuel Cell Technology Experimentation in Spain equipped with installations that enable scientific and technological design, develop, verify, certify, approve, test, measure and, more importantly, the facility ensures continuous operation for 24 hours a day, 365 days year. At the same time, the system is scalable so as to allow continuous adaptation of new technologies are developed and incorporated into the assembly to verify integration at the same time it checks the validity of their development. The transformation sector can be said to be the heart of the system, because without neglecting the other sectors, this should prove the validity of hydrogen as a carrier - energy storage are important efforts that have to do to demonstrate the suitability of fuel cells or internal combustion systems to realize the energy stored in hydrogen at prices competitive with conventional systems. The multiple roles to meet the fuel cells under different conditions of operation require to cover their operating conditions, many different sizes and applications. The fourth area focuses on integration is an essential complement within the installation. We must integrate not only the electricity produced, but also hydrogen is used and the heat generated in the process of using hydrogen energy. The energy management in its three forms: hydrogen chemical, electrical and thermal integration requires complicated and require a logic and artificial intelligence extremes to ensure maximum energy efficiency at the same time optimum utilization is achieved. Verification of the development and approval in the entire production system and, ultimately, as a demonstrator set to facilitate the simultaneous evolution of production technology, storage and distribution of hydrogen fuel cells has been assessed.

Interactive Graphic Simulation: An Advanced Methodology to Improve the Teaching-Learning Process in Nuclear Engineering Education and Training

Nowadays, computer simulators are becoming basic tools for education and training in many engineering fields. In the nuclear industry, the role of simulation for training of operators of nuclear power plants is also recognized of the utmost relevance. As an example, the International Atomic Energy Agency sponsors the development of nuclear reactor simulators for education, and arranges the supply of such simulation programs. Aware of this, in 2008 Gas Natural Fenosa, a Spanish gas and electric utility that owns and operate nuclear power plants and promotes university education in the nuclear technology field, provided the Department of Nuclear Engineering of Universidad Politécnica de Madrid with the Interactive Graphic Simulator (IGS) of “José Cabrera” (Zorita) nuclear power plant, an industrial facility whose commercial operation ceased definitively in April 2006. It is a state-of-the-art full-scope real-time simulator that was used for training and qualification of the operators of the plant control room, as well as to understand and analyses the plant dynamics, and to develop, qualify and validate its emergency operating procedures.

Eco-entrepreneurship in developing countries: the case of renewable energy sector in Bolivia

The change towards a sustainable economic system represents a big challenge for the present as well as next generations. Such a process requires important long-term changes in technologies, lifestyle, infrastructures and institutions. In this scenario the innovation process is a crucial element for fostering sustainability as well as an egalitarian development in developing countries. For those reasons the concept of Eco-Innovation System is introduced and further considerations are provided for the case of less-developed countries. The paper illustrates that sustainable development is possible by exploiting local potential and traditional knowledge in order to achieve at the same time economic growth, social equality and environmental sustainability. In order to prove such an assumption a specific case study is described: The renewable energy sector in Bolivia. The case study summarizes many important dimensions of the innovation process in developing countries such as technological transfer, diffusion and adaptation, social dimension and development issues.

New Constructive Solutions to Improve Energy Efficiency in Existing Buildings and their Economic Viability

The improvement of energy efficiency in existing buildings is always a challenge due to their particular, and sometimes protected, constructive solutions. New constructive regulations in Spain leave a big undefined gap when a restoration is considered because they were developed for new buildings. However, rehabilitation is considered as an opportunity for many properties because it allows owners to obtain benefits from the use of the buildings. The current financial and housing crisis has turned society point of view to existing buildings and making them more efficient is one of the Spanish government’s aims. The economic viability of a rehabilitation action should take all factors into account: both construction costs and the future operative costs of the building must be considered. Nevertheless, the application of these regulations in Spain is left to the designer’s opinion and always under a subjective point of view. With the research work described in this paper and with the help of some case-studies, the cost of adapting an existing building to the new constructive regulations will be studied and Energetic Efficiency will be evaluated depending on how the investment is recovered. The interest of the research is based on showing how new constructive solutions can achieve higher levels of efficiency in terms of energy, construction and economy and it will demonstrate that Life Cycle Costing analysis can be a mechanism to find the advantages and disadvantages of using these new constructive solutions. Therefore, this paper has the following objectives: analysing constructive solutions in existing buildings - to establish a process for assessing total life cycle costs (LCC) during the planning stages with consideration of future operating costs - to select the most advantageous operating system – To determine the return on investment in terms of construction costs based on new techniques, the achieved energy savings and investment payback periods.

Evaluation of the In desorption during the capped process in diluted nitride In(Ga)As quantum dots

Diluted nitride self-assembled In(Ga)AsN quantum dots (QDs) grown on GaAs substrates are potential candidates to emit in the windows of maximum transmittance for optical fibres (1.3-1.55 μm). In this paper, we analyse the effect of nitrogen addition on the indium desorption occurring during the capping process of InxGa1−xAs QDs (x = l and 0.7). The samples have been grown by molecular beam epitaxy and studied through transmission electron microscopy (TEM) and photoluminescence techniques. The composition distribution inside the dots was determined by statistical moiré analysis and measured by energy dispersive X-ray spectroscopy. First, the addition of nitrogen in In(Ga)As QDs gave rise to a strong redshift in the emission peak, together with a large loss of intensity and monochromaticity. Moreover, these samples showed changes in the QDs morphology as well as an increase in the density of defects. The statistical compositional analysis displayed a normal distribution in InAs QDs with an average In content of 0.7. Nevertheless, the addition of Ga and/or N leads to a bimodal distribution of the Indium content with two separated QD populations. We suggest that the nitrogen incorporation enhances the indium fixation inside the QDs where the indium/gallium ratio plays an important role in this process. The strong redshift observed in the PL should be explained not only by the N incorporation but also by the higher In content inside the QDs

Cost and energy efficient reconfigurable embedded platform using Spartan-6 FPGAs

Modern FPGAs with run-time reconfiguration allow the implementation of complex systems offering both the flexibility of software-based solutions combined with the performance of hardware. This combination of characteristics, together with the development of new specific methodologies, make feasible to reach new points of the system design space, and make embedded systems built on these platforms acquire more and more importance. However, the practical exploitation of this technique in fields that traditionally have relied on resource restricted embedded systems, is mainly limited by strict power consumption requirements, the cost and the high dependence of DPR techniques with the specific features of the device technology underneath. In this work, we tackle the previously reported problems, designing a reconfigurable platform based on the low-cost and low-power consuming Spartan-6 FPGA family. The full process to develop the platform will be detailed in the paper from scratch. In addition, the implementation of the reconfiguration mechanism, including two profiles, is reported. The first profile is a low-area and low-speed reconfiguration engine based mainly on software functions running on the embedded processor, while the other one is a hardware version of the same engine, implemented in the FPGA logic. This reconfiguration hardware block has been originally designed to the Virtex-5 family, and its porting process will be also described in this work, facing the interoperability problem among different families.

Study of the Mechanical Strength Improvement of Wafers for EWT Solar Cells by Chemical Etching after the Drilling Process

Mechanical stability of EWT solar cells deteriorates when holes are created in the wafer. Nevertheless, the chemical etching after the hole generation process improves the mechanical strength by removing part of the damage produced in the drilling process. Several sets of wafers with alkaline baths of different duration have been prepared. The mechanical strength has been measured by the ring on ring bending test and the failure stresses have been obtained through a FE simulation of the test. This paper shows the comparison of these groups of wafers in order to obtain an optimum value of the decreased thickness produced by the chemical etching

GreenDisc: a HW/SW energy optimization framework in globally distributed computation

In recent future, wireless sensor networks (WSNs) will experience a broad high-scale deployment (millions of nodes in the national area) with multiple information sources per node, and with very specific requirements for signal processing. In parallel, the broad range deployment of WSNs facilitates the definition and execution of ambitious studies, with a large input data set and high computational complexity. These computation resources, very often heterogeneous and driven on-demand, can only be satisfied by high-performance Data Centers (DCs). The high economical and environmental impact of the energy consumption in DCs requires aggressive energy optimization policies. These policies have been already detected but not successfully proposed. In this context, this paper shows the following on-going research lines and obtained results. In the field of WSNs: energy optimization in the processing nodes from different abstraction levels, including reconfigurable application specific architectures, efficient customization of the memory hierarchy, energy-aware management of the wireless interface, and design automation for signal processing applications. In the field of DCs: energy-optimal workload assignment policies in heterogeneous DCs, resource management policies with energy consciousness, and efficient cooling mechanisms that will cooperate in the minimization of the electricity bill of the DCs that process the data provided by the WSNs.

Renewable energy infrastructure. A challenge for Venezuelan industrial construction

The relevance of renewable energy has grown significantly in our global society. Important efforts are oriented to sustain it. Renewable energy depends on different technical, financial environmental and social complex processes. From the point of view of industrial construction sector this research evaluates some of the current trends in energy generation and use in Venezuela as well as environmental consequences and risks that derive from these. Additionally, authors highlight the importance of infrastructure as key issue to sustain renewable energy generation and use. The study present references of some energy renewable projects in process in Venezuela and the main problems that constrain their performance. Conclusions evidence the complex nature of industrial construction and suggest the need to improve industrial construction competitivenes as a strategy oriented to enhance renewable energy offer in the country. Additionally it is proposed to all stakeholders to work toghether to correct the conditions that currently limit industrial construction development. This is part of ongoing research.

GreenDisc: a HW/SW energy optimization framework in globally distributed computation

In recent future, wireless sensor networks ({WSNs}) will experience a broad high-scale deployment (millions of nodes in the national area) with multiple information sources per node, and with very specific requirements for signal processing. In parallel, the broad range deployment of {WSNs} facilitates the definition and execution of ambitious studies, with a large input data set and high computational complexity. These computation resources, very often heterogeneous and driven on-demand, can only be satisfied by high-performance Data Centers ({DCs}). The high economical and environmental impact of the energy consumption in {DCs} requires aggressive energy optimization policies. These policies have been already detected but not successfully proposed. In this context, this paper shows the following on-going research lines and obtained results. In the field of {WSNs}: energy optimization in the processing nodes from different abstraction levels, including reconfigurable application specific architectures, efficient customization of the memory hierarchy, energy-aware management of the wireless interface, and design automation for signal processing applications. In the field of {DCs}: energy-optimal workload assignment policies in heterogeneous {DCs}, resource management policies with energy consciousness, and efficient cooling mechanisms that will cooperate in the minimization of the electricity bill of the DCs that process the data provided by the WSNs.

Progress on optimization of the solar cell fabrication process by impurity-to-efficiency predictive simulator

To optimize the last high temperature step of a standard solar cell fabrication process (the contact cofiring step), the aluminium gettering is incorporated in the Impurity-to-Efficiency simulation tool, so that it models the phosphorus and aluminium co-gettering effect on iron impurities. The impact of iron on the cell efficiency will depend on the balance between precipitate dissolution and gettering. Gettering efficiency is similar in a wide range of peak temperatures (600-850 ºC), so that this peak temperature can be optimized favoring other parameters (e.g. ohmic contact). An industrial co-firing step can enhance the co-gettering effect by adding a temperature plateau after the peak of temperature. For highly contaminated materials, a short plateau (menor que 2 min) at low temperature (600 ºC) is shown to reduce the dissolved iron.

Damage reduction of the laser drilling process on back contact solar cells by chemical treatment

Production of back contact solar cells requires holes generations on the wafers to keep both positive and negative contacts on the back side of the cell. This drilling process weakens the wafer mechanically due to the presence of the holes and the damage introduced during the process as microcracks. In this study, several chemical processes have been applied to drilled wafers in order to eliminate or reduce the damage generated during this fabrication step. The treatments analyzed are the followings: alkaline etching during 1, 3 and 5 minutes, acid etching for 2 and 4 minutes and texturisation. To determine mechanical strength of the samples a common mechanical study has been carried out testing the samples by the Ring on Ring bending test and obtaining the stress state in the moment of failure by FE simulation. Finally the results obtained for each treatment were fitted to a three parameter Weibull distribution